1988–1995 Kawasaki EL250 Eliminator, 250HS Service Manual Set (P/N 99924-1066-01)

Covering the EL250-B2/B3 Eliminator 250 and EL250-E1 250HS, this Kawasaki service manual set pairs the EL250 supplement, second edition dated June 8, 1990, with the Ninja250R/GPZ250R base manual, P/N 99924-1066-01.

Text search, navigation, and wiring detail: Neither PDF supports text search or includes bookmarks. Navigation uses the printed quick-reference guides and chapter contents; small wire-color codes and component labels are readable when enlarged.

• Carburetor repair: Removal, disassembly, cleaning, inspection, synchronization, and fuel-level adjustment for the Keihin CVK units.

• Cooling system: Pressure testing, radiator-cap and thermostat inspection, water-pump removal and installation, and coolant bleeding.

• Engine top end: Compression testing, cylinder-head repair, valve-clearance adjustment, valve-seat refinishing, camshaft-chain timing, and piston-ring inspection.

• Engine and transmission: Engine removal, crankcase splitting, crankshaft and balancer inspection, wet multi-plate clutch service, and six-speed transmission repair.

• Brakes: Front caliper and master-cylinder repair with hydraulic bleeding, plus EL250 rear-drum shoe and brake-cam inspection.

• Suspension and steering: Fork disassembly and seal replacement, twin-shock adjustment, swingarm-bearing inspection, and steering-stem service.

• Electrical diagrams: Full-vehicle wiring layouts for EL250-B2/B3 Early, EL250-B3 Late, and EL250-E1, alongside component tests and individual circuit diagrams.

Written primarily for mechanics working in an equipped shop, these manuals also support basic owner maintenance and repair. Owners need mechanical knowledge, correct tools, and familiarity with workshop procedures; jobs beyond their experience require a qualified mechanic.

EL250 Specifications and Model Differences

Using both manuals: The EL250 supplement documents the model-specific changes, while the EX250-E1/E2 base manual provides the shared repair procedures. Using them together lets mechanics check component wear and plan rebuilds against the correct factory data.

Chassis and carburetors: The EL250 uses CVK30 carburetors, a rear drum brake, and twin rear shocks. Its supplement overrides the base manual’s CVK32, rear-disc, and Uni-Trak information, preventing selection of the wrong specifications or procedures; the 250HS adds its own EL250E section.

Cooling-system revision: The Cooling System exploded view marks the water-pump and coolant-pipe change from engine No. EX250EE034395 onward.

California evaporative-emission coverage includes canister and liquid/vapor separator inspection, hose routing, and separator-operation tests.

Crankshaft, Transmission, and Engine Repair

Bearing selection: Color-coded bearing-insert tables connect crankpin and main-journal measurements with component identification marks. EL-specific selection data help identify replacement inserts for crankshaft repair.

Gearbox and lubrication: Transmission inspection covers shift forks, drum grooves, gear-dog wear, and the positive neutral finder mechanism. Lubrication and assembly notes accompany exploded views, and the Engine Oil Flow Chart relates oil routing to the oil-pressure and relief-valve checks.

Final-drive coverage: The base PDF omits printed pages 10-4 and 10-5. The EL250 supplement documents final-drive changes but does not replace the missing base procedures.

Repair cautions: Top-end notes explain that incorrectly located camshaft caps can change bearing clearance and seize a camshaft. Carburetor cleaning cautions describe float and vacuum-piston diaphragm damage from compressed air applied to an assembled unit.

Electrical Tests and Fault Tracing

Charging, ignition, and starting: Electrical diagnosis covers the alternator, regulator/rectifier, ignition coils, and IC igniter. Starter-motor inspection extends to brush wear, the commutator, and the armature.

Relays and model-specific circuits: The Junction Box Internal Circuit supports relay, diode, and continuity checks. Cooling-fan diagrams distinguish early and late B3 circuits, while EL250-E1 documentation adds tachometer and coolant-temperature warning-system tests.

Symptom diagnosis: The troubleshooting guide links starting difficulties, poor running, overheating, clutch malfunction, and gear-selection faults to potential causes.

Torque References and Workshop Tools

Service limits and test data: Component torque tables accompany fluid capacities, clearances, wear limits, and electrical test values. Cylinder-head bolts and axle nuts are among the fasteners with torque figures in newton-meters and foot-pounds.

Specified equipment: Tool references include the Fuel Level Gauge 57001-1017, Clutch Holder 57001-1243, and Coil Tester 57001-1242. These identify the equipment used in fuel-system, clutch, and ignition procedures.

Manufacturer precautions address fuel handling, brake service, and unexpected cooling-fan operation, alongside the component service limits.

PDF Set and Additional Diagrams

The 368-page set consists of a 131-page EL250 supplement and a 237-page Ninja250R/GPZ250R base manual. Each PDF’s count includes its seven preliminary pages; the 14-page EL250E section is included in the supplement. The accompanying 54 parts illustrations and one EL250-E wiring image are separate files and are excluded from the PDF page count.